System and method for obtaining and utilizing maintenance information

ABSTRACT

A system for obtaining, recording, displaying, storing, transmitting and receiving maintenance and other information is provided. The system, which may include an electronic maintenance apparatus that may be in the form of a hand-held digital computer, allows a user to capture and store images, sound, and/or error codes and related text or voice data and other information concerning the system or object being maintained. The information can be stored locally and/or transmitted to remote locations. Retrieval of the images and other data at a later date provides an historical perspective of the object, enabling one using the maintenance apparatus to compare and contrast the condition of the object over time. Instruction on how to accomplish a job at hand, diagnostic information and/or support information may also be transmitted to and from the maintenance apparatus.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 60/231,913, filed Sep. 11, 2000.

BACKGROUND

1. Field of the Invention

The present invention relates to maintenance systems and, moreparticularly, to systems and methods for obtaining and utilizingmaintenance information.

2. Related Art

Maintenance logs are used to record maintenance information by personnelperforming maintenance and inspection on objects, such as motors,aircraft, boats, machines, structures and buildings. These maintenancelogs typically include information regarding the condition of the objectand/or the work being performed on the object, and provide an historicalrecord of such information. Typical logs take the form of notebooks,whereby the person performing the maintenance can write descriptions ofthe condition of the object and/or the work performed. The log can bemaintained as a reference point for future maintenance and performanceinformation regarding the object.

SUMMARY OF THE INVENTION

In one embodiment, a method of maintaining an object is provided. Themethod comprises the acts of storing, in digital format, a first imageof the object at a first time, obtaining a second image of the object ata second time, comparing the first image to the second image, anddetermining whether to perform maintenance on the object based, at leastin part, on the act of comparing.

In another embodiment, a method of inspecting an object from a remotelocation is provided. The method comprises the acts of obtaining adigital image of the object at a first location, electronicallytransmitting the digital image to a second location remote from thefirst location, viewing the digital image at the second location,transmitting instructions to the first location, and performing an acton the object in response to the instructions.

In yet another embodiment, an electronic inspection apparatus isprovided. The apparatus is adapted to communicate with a camera toobtain an image of an object is provided. The apparatus comprises acasing, a computer disposed within the casing, and a camera control unitdisposed within the casing and coupled to the computer. The cameracontrol unit is adapted to receive electronic images from the camera,reformat the electronic images into digital format and pass thedigitally formatted images to the computer. The apparatus also includesan input device, coupled to the computer, that is adapted to allow auser to input full text data relating to the image.

In still another embodiment, an electronic inspection apparatus isprovided. The apparatus is adapted to communicate with a camera toobtain an image of an object. The apparatus comprises a casing, acomputer disposed within the casing, and a camera control unit disposedwithin the casing and coupled to the computer. The camera control unitis adapted to receive electronic images from the camera, reformat theelectronic images into digital format and pass the digitally formattedimages to the computer. The apparatus further includes a computerreadable storage medium, coupled to the computer, having an executablecode stored thereon. The code allows the computer to execute at leasttwo processes in a multitask fashion.

In another embodiment, an electronic inspection apparatus is providedthe apparatus is adapted to communicate with a camera for obtaining animage of an object. The apparatus comprises a casing, a computerdisposed within the casing, and a control unit disposed within thecasing and coupled to the computer. The control unit is adapted tocommunicate with the camera. The apparatus further includes an inputdevice coupled to the computer and the control unit. The input device isadapted to receive an input command from a user. The control unit isadapted to receive the command and signal at least portions of thecamera to react as commanded.

In another embodiment, an aircraft inspection system is provided. Thesystem includes a camera adapted to view a component of the aircraft,and a portable electronic apparatus communicating with the camera. Theapparatus includes a casing, a computer disposed within the casing, anda camera control unit coupled to the computer and disposed within thecasing. The camera control unit is adapted to receive an image from thecamera and pass the image to the computer. The apparatus also includes adisplay coupled to the computer that is adapted to display the image. Aninput device is coupled to the computer and is adapted to allow a userto input maintenance data relating to the component. The apparatusfurther includes a storage medium communicating with the computer. Thestorage medium is adapted to store the image and related data.

In yet another embodiment, an electronic maintenance apparatus isprovided. The apparatus is adapted to communicate with a camera toobtain an image of an object. The apparatus comprises a casing, acomputer disposed within the casing, and a storage medium communicatingwith the computer. The storage medium includes maintenance informationregarding the object being imaged.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the invention will now be described, by way ofexample, with reference to the accompanying drawings, in which:

FIG. 1 is a schematic representation of a maintenance system accordingto one aspect of the invention;

FIG. 2 is an illustration of an exemplary use of the system of FIG. 1;

FIG. 3 is a perspective view of a maintenance apparatus for use with thesystem according to one embodiment of the invention;

FIG. 4 is an exploded perspective view of the maintenance apparatus ofFIG. 3;

FIG. 5 is a view of the maintenance apparatus of FIG. 3 showing anexample of a display provided by the maintenance apparatus;

FIG. 6 is a partially cut away perspective view of an imaging system foruse with the maintenance apparatus of FIGS. 3-5;

FIG. 7 is a partially cut away perspective view of the imaging systemshown in FIG. 6;

FIGS. 8a and 8 b are partially cut away perspective views of anillustrative focusing mechanism employed in the system of FIGS. 6-7;

FIG. 9 is a partially cut away perspective view of an alternativeembodiment of the imaging system including an adapter that adapts astandard camera head to be mated with a coupler shown in the system ofFIGS. 6-7; and

FIG. 10 is a partially cut away perspective view of the adapter shown inFIG. 9.

DETAILED DESCRIPTION

Applicant's have appreciated that, after a short period of time,conventional log notebooks can become voluminous, torn, dirty, lost ordestroyed. And, if they are to be read by people in places other thanwhere they are stored, they must be copied and shipped, faxed, ortransported in some manner to the desired location. Maintaining thesenotebooks is time consuming, costly and antiquated at best.

In one embodiment, a system for obtaining and storing maintenanceinformation in electronic format is provided. The system includes anapparatus having an LCD, a touch panel, a camera connector, cameraadjustments and a flashcard port. The apparatus houses a camera controlunit (CCU) and a computer, which are used to receive and process imagesfrom an imager which is attached to the apparatus at the cameraconnector. This CCU and computer are also used to process images anddata and place these images and data on a storage media such as aflashcard, which may be removably placed in the flashcard port. Theapparatus also has attachment connectors for an external keyboard if oneis desired by the user, external computer display video OUT andconnectors as well as battery and external power connectors.

The apparatus may be used by maintenance personnel to capture images ofthe equipment or objects they are inspecting or maintaining as well asenter notes or detailed descriptions in writing or voice recording asadjuncts to the aforementioned images. The apparatus may also bewearable, battery powered, voice or touch activated. Once the picturesand data are captured and stored, they may be down loaded to othercomputers and or transmitted via the Internet or other transportmethods. The storage media may be maintained with the apparatus in aseparate housing carrying/storage case for permanent records that maystay with the apparatus for further reference.

It should be appreciated that the apparatus may use storage media whichhas been preformatted with desired maintenance programs that couldcontain parts list, training material, instructions for use,instructions on how to accomplish a job at hand, check list, operationsmanuals and other material not limited to the aforementioned.

Another feature is that the apparatus will enable the user to keep andmaintain a wear history on mechanical objects (e.g., engine components)thus enabling the user to make judgments on when a part might fail priorthe part actually failing.

Another embodiment of the present invention is directed to a method ofmaintaining a digital maintenance information. One embodiment of thepresent invention relates to a method of maintaining a digitalmaintenance information that includes pictures and/or text concerningthe system being maintained. The use of pictures is particularlypowerful, as it enables one viewing the maintenance apparatus to compareand contrast the manner in which a component of the system has worn overtime. It should be appreciated that any suitable type of camera can beused to take such pictures.

In one embodiment of the present invention, a set of pictures can betaken of key components of a system before the system is sent to thecustomer. Thereafter, during periodic maintenance checks, additionalpictures can be taken, which can enable one to view the maintenanceapparatus to compare the way the parts have worn.

In one embodiment of the invention, a computer readable medium can beinstalled on the system to be maintained, so that the maintenance filecan be stored therein. Optionally, the storage medium provided with thesystem can include pictures of certain components of the system wheninitially shipped to the customer, although the aspect of the presentinvention related to installing the digital maintenance file on thesystem to be maintained is not limited in this respect. Also, it shouldbe appreciated that the embodiment of the present invention relating toinstalling the storage medium that stores the digital maintenance fileon the system to be maintained is not limited to the use of aphotographic maintenance file, as embodiments of the present inventioncontemplate that merely a text maintenance file can be employed.

It should be appreciated that it is an advantage of one embodiment ofthe present invention that the digital maintenance file is mounted tothe system to be maintained, such that the maintenance file always stayswith the system and can be accessed by maintenance personnel whereverthe system is present, and further, cannot be lost. In addition, themaintenance file can be backed up and stored away from the system to bemaintained to enhance the security of the data that comprises thedigital maintenance file.

In another embodiment of the present invention, the apparatus can beprovided with a video output, such that videotapes can be made of thedigital pictures taken.

In another embodiment of the present invention, maintenance personnelcan be provided with a remote system for recording digital information(photographic and/or text) while inspecting the system into a computerreadable medium that they can carry around with them. This remote systemcan be cordless for ease of use (e.g., it can be battery powered). Oncethe inspection is complete, the remote system can be coupled to thestorage medium installed on the system to be maintained and theinformation from the maintenance inspection can be downloaded into thedigital maintenance file on the system.

Such a maintenance apparatus can be used with numerous types of systems,including aircraft (e.g., airplanes and helicopters), boats,automobiles, trucks, military equipment (e.g., tanks, etc.) and othersystems as will be explained below.

One embodiment is directed to a method and apparatus for obtaining,recording, displaying, storing, transmitting and/or receivingmaintenance and other information electronically, allowing a user tocapture and store images, sound, error codes, related text or voice dataand/or other information concerning the system or object beingmaintained. The information can be stored locally and/or transmitted toremote locations. Retrieval of the images and other information at alater date provides an historical perspective of the object, enablingone using the maintenance apparatus to compare and contrast thecondition of the object over time. Instruction on how to accomplish ajob at hand, diagnostic information and/or support information may alsobe transmitted to and from the maintenance apparatus. Such informationmay alternatively be pre-stored for later retrieval.

In one embodiment, the maintenance apparatus may be used as an interfacebetween the object to be inspected and the person performing theinspection. The apparatus allows a user to receive maintenanceinformation, such as historical and/or real-time information regardingthe object, and determine a course for corrective action to be performedon the object as necessary. In this manner, a user may make maintenancejudgments, such as, for example, whether the object needs maintenance orwhen the object might fail prior the object actually failing.

In one embodiment shown in FIG. 1, a maintenance system 10 includes amaintenance apparatus 20 that receives real-time or current data 22 aconcerning the condition of one or more objects 24, such as a mechanicalcomponent, being inspected. The data 22 a concerning the object mayrelate to physical characteristics of the object 24, the interaction oftwo or more physical components, the operation of any object, such asthe operating characteristics of any physical or electronic component,or any other characteristic of the object, as the present invention isnot limited to receiving any particular types of data. The data 22 a maybe in the form of one or more images 26, audio 28 (e.g., the sound ofthe object as it functions), error codes 30, any suitable combinationthereof, or any other data, as the present invention is not limited inthis respect. The image 26 of the object may be generated by any imageproducing device as invention not limited in this respect. Similarly,audio 28 may be obtained with the use of any suitable device (e.g., amicrophone), and the error code 30 may be obtained with any suitableinterface. Notes or detailed descriptions in text format 32 or voicerecording 34 may be input into the apparatus 20 as adjuncts to theaforementioned data 22 a and may be inputted using a user interface 36.The data 22 a may be presented to a user using one or more suitableoutput devices 38.

The maintenance apparatus 20 may store the data (labeled as 22 b inFIG. 1) locally (e.g., in a storage medium of the apparatus 20) orremotely (e.g., at a central maintenance facility). The local storagemedium may be internal or external to the apparatus 20 (e.g., in aseparate housing carrying/storage case (not shown)), thereby providing arecord that may stay with the apparatus 20 for further reference.

In one embodiment, the apparatus may provide access to maintenanceinformation that may include, in addition to the present data 22 bconcerning the object, any one or more of the following: informationregarding the initial condition 39 of the object; historical information40 of the object; diagnostic information 42; instructional information44 (e.g., parts list, training materials, instructions for use,instructions on how to accomplish a job at hand, check lists, operationsmanuals, layout information, schematic and parts diagrams, objectlocation diagrams, etc.); and support 46 (e.g., help menu and/or realtime technical assistance from technical support personnel when theapparatus is communicating with a maintenance facility ormanufacturer/provider of the object 24). Such additional information maybe stored locally (e.g., within the apparatus 20) or remotely, with theapparatus 20 having the capability to communicate with the remotelocation. Any of the above described information can be employed withthe apparatus in any suitable combination.

The historical information 40 may be provided using any suitabletechnique. In one embodiment, the historical information 40 may includea compilation of maintenance and inspection data 22 b previouslyobtained by the user or users. Data concerning the initial condition 39of an object may be provided to a customer of the system for subsequentcomparison with real time information. For example, a set of images canbe taken of key components of a system before the system is sent to acustomer. During periodic maintenance checks, additional images can betaken, which can enable one to view the maintenance apparatus to comparethe current data with the initial condition information or historicalinformation to determine the way the parts have worn.

As discussed above, in one embodiment, the system can communicate with aremote facility. This provides a number of advantages. For example, asmay be the case with aircraft, maintenance for certain objects may beperformed at different locations. Using the remote communicationability, an inspector at a first location may record his or herobservations and upload the data 22 b to a central database, so that aninspector at a second location may download that data prior toperforming a subsequent inspection on the same aircraft.

In other embodiments of the invention, other techniques for providing auser with the most current data may be employed. For example, in oneembodiment, a computer readable medium can be installed on the object tobe maintained (e.g., installed on an aircraft), so that the maintenanceinformation can be stored therein. Optionally, the storage mediumprovided with the object can include any of the types of data describedabove, including pictures of certain components of the object wheninitially shipped to the customer, although the aspect of the inventionrelated to installing the maintenance information on the system to bemaintained is not limited in this respect. Also, it should beappreciated that the embodiment of the present invention relating toinstalling the storage medium that stores the maintenance information onthe object to be maintained is not limited to the use of image data, asembodiments of the present invention contemplate that text, audio, errorcode and/or other data can be employed.

An advantage of installing the maintenance information on the object tobe maintained is that the maintenance information always stays with theobject and can be accessed by maintenance personnel wherever the objectis present, and cannot be lost. Once the inspection is complete, theapparatus can be coupled to the storage medium installed on the objectto be maintained and the information from the maintenance inspection canbe downloaded into the file stored on the object. In addition, themaintenance information can be backed up and stored away from the objectto enhance the security of the data that comprises the maintenanceinformation.

Referring in relation to aircraft as shown in FIG. 2, an exemplary useof the maintenance system 10 will be described. A maintenance worker orinspector 50 inspects an engine 52 of an airplane using the maintenanceapparatus 20 according to one embodiment of the present invention. Theinspector 50 probes into the engine compartment 53 using a suitable datainput device (such as a camera, scope, microphone, etc., (not shown))coupled to the apparatus 20 via a link 54. An inspection port 55 formedon the engine housing 53 may be used to facilitate inserting the inputdevice to enable the user to obtain the desired data. Data 22 b (FIG. 1)is captured by the apparatus 20 for subsequent processing and analysis.In one embodiment, the inspector 50 inserts a camera 50 into the enginecompartment to obtain an image of the engine.

The inspector 50, after obtaining the data, may record additional data,such as notes regarding the condition of the engine, the serial numberof the engine, the date of inspection, the aircraft tail number or otheridentifier, the inspector's name, etc. This can be performed using auser interface 36 (FIG. 1) or the apparatus 20, which can be a keyboard,touch screen or any suitable interfaces as will be described below. Theinspector 50 may also recall previously stored information regarding theengine, such as the aforementioned initial condition 39, historicalinformation 40, diagnostic information 42 or instructional information,44 and determine a course of action.

As discussed above, in one embodiment, the apparatus 20 may communicatewith a remote facility through a suitable communications link (shown as56 in FIG. 2). Link 56 can be any suitable communication medium,including wireless communication. The remote facility may include acomputer 57 storing a database (not shown) capable of storing any of theabove mentioned information concerning the object being inspected.Technicians at the remote facility may be able to remotely obtain andanalyze the information obtained by the apparatus 20 to provide guidanceto the inspector 50 regarding any action necessary. The communication ofthe apparatus with the remote facility enables technicians at a remotesite to obtain the data in real time, thereby enhancing maintenanceefficiency. Alternatively, the technician at the remote facility mayview and analyze the maintenance information at a later time.

The maintenance apparatus 20 may also be used as a communicationinterface between an inspection facility and the object 24 beinginspected. In this manner, an inspector can be posted at the remotelocation while a helper is located on site to manipulate the apparatus20 and/or its associated data gathering device(s). This enables theremote inspector to obtain real time data and render a maintenancedecision from a remote location without the need for a skilledtechnician on site with the object being inspected.

Rather than probe the object 24 to be inspected with a data gatheringdevice coupled to the apparatus 20, one or more data gathering devicesmay be installed on the object to be inspected, with the apparatus 20being capable of communicating with these devices. For example, anaircraft, ship or other object may be outfitted with several camerascapable of viewing certain areas within the object. The apparatus 20 maycommunicate with each of these cameras, via hardwire or wirelessconnection, to receive an image of the area to be inspected. Multipleviews may also be generated to view an area from different locationsand/or to view the interaction of multiple components.

The maintenance apparatus 20 may be implemented in any suitable manner,as the present invention is not limited in this respect. In oneembodiment, the maintenance apparatus 20 is implemented as a portablehand-held digital computer/camera assembly. As is explained more fullybelow with reference to FIGS. 3-5, the assembly may be housed within acasing, resulting in the approximate size and weight of a laptopcomputer. For example, the hand-held apparatus may be up to about ten tofourteen inches long, up to about eight to twelve inches wide, and up toabout one to four inches thick. The apparatus 20 may include orotherwise communicate with a storage medium and may also include a powersource (e.g., a battery pack) that renders the apparatus cordless andeasily transportable. In one embodiment, the apparatus 20 is less thanabout ten pounds. More preferably, the apparatus 20 is less than aboutfive pounds, and most preferably, less than about three pounds. Itshould be appreciated that the power pack may comprise a largepercentage of the weight. Thus, the weight of the apparatus 20 dependsupon the size of the power pack included within the apparatus 20. Withsuch a hand-held apparatus, increased portability and ease of use may beattained.

The illustrative embodiment of the apparatus 20 shown in FIGS. 3-5includes several main components, including input devices 70 a-70 f,output devices 80 a, 80 b, 70 b, 70 c, a motherboard 90, a cameracontrol unit 100, a video chip 110, and a casing 130, each of which willbe discussed in more detail below. As discussed above, the data input todevices and the data output devices may be any number of devices, eitherinternal to the apparatus or connected externally via any number oftechniques, and in some instances, the input and output devices may bepart of the same device. The data being inputted to or outputted fromthe apparatus 20 may be in any format, including but not limited to,still image data, streaming video images, text and audio, and may besent to or received by the apparatus as desired. The motherboard 90includes a central processing unit (CPU) 92, computer readable storagemedium 94 coupled to the CPU 92 (e.g., via a bus (not shown)), and atleast one input/output (I/O) connection 95 coupled to the CPU 92. Themotherboard can be custom designed or can be any of a number of standarddevices. The motherboard 90 controls data flow and storage, and works inconjunction with the video chip 110 and camera control unit 100 (CCU) tofacilitate image processing and display.

The input devices 70 a-70 f provide the apparatus 20 with data. At leastone of the devices provides a user interface. A user may be human ornon-human, as in the case of an application program or another device.Any of a number of input devices may be employed. The apparatus 20 mayhave any number of internal input devices, disposed within the confinesof the casing of the apparatus, as well as any number of externaldevices through suitable connections. The input devices can includecontrol units, such as buttons, knobs or switches, keypads, touchscreen, the other input devices and the output devices etc. to controlvarious aspects of the apparatus. Human user input can also be obtainedfrom an externally connected mouse, keyboard, joystick, glove, headset,microphone or any other manually controlled devices.

In one embodiment, a touch screen 70 a is employed for human user input.In this embodiment, a touch screen controller 72 is connected to thetouch screen 70 a and the motherboard 90 and transfers the data from thetouch screen 70 a to the motherboard 90 for further processing andstorage. Any of aforementioned external input or output devices may beattached to the apparatus 20 in numerous ways, via, for example, aconnection port 74. The apparatus may also include voice recognitionsoftware, so that data may be input or the system may be controlled byvoice. Voice recordings may also be stored in the apparatus 20.

Maintenance information previously stored on internal or externalstorage devices may also be inputted to the apparatus 20. Any suitablestorage device may be employed, including the internal memory of themotherboard 90, harddrives or other storage media. In one embodiment, aflashcard 70 b may be employed as a storage medium and may be installedthrough a PCMCIA (Personal Computer Memory Card InternationalAssociation) card port 76. The flashcard 70 b may be in addition to thememory already present on the motherboard 90. The flashcard 70 b may beremovable through the slot, or permanently attached to the apparatus 20and contained within the device via a detachable, protective, screw-oncovering 78. The card can be used to store preconfigured data.

Information stored on other devices can also be transmitted to theapparatus 20 via any of numerous communication mediums 70 c, includingbut not limited to wireless communication media, such as cellular,satellite or infrared communication, modem connections, Ethernetconnections, etc may be made through the PCMCIA port 76. Hardwareenabling these communication mechanisms may be internal to the apparatus20 in some embodiments and connected externally in others. Additionally,information may be transferred into the apparatus 20 via any of thenumerous devices, for example: magnetic media (e.g., videotapes,audiotapes or floppy disks), optical media (e.g., CDs DVDs or laserdisks), and electronic media (e.g., EPROM). One method of connection forany video input is an S-Video (Super-Video) connection port 79 hardwiredto an S-Video-compatible device capable of reading the product. However,the present invention is not limited to this type of connection, asports and devices formatted for other types of video signals may beemployed, including, for example, a composite signal.

As discussed above, in one embodiment the apparatus 20 is capable ofreceiving images from a camera, such as camera 70 d shown in FIG. 3. Anysuitable camera or cameras may be used, as the present invention is notlimited in this respect. In one embodiment, the camera 70 d is NTSC(National Television Standards Committee) compatible. NTSC is the one ofseveral camera standards used in the United States. Examples of camerasthat may be used with the apparatus 20 include the BoreCam™, thePeriCam™, the TeleCam™, and the ToolCam™, each available from VisionTechnologies of Rogers, AR. Alternatively, cameras compatible with othertelevision broadcast standards may be used, including those compatiblewith the PAL (Phase Alternate Line) or SECAM (Systeme ElectroniqueCouleur Avec Memoire) systems, or any other type of camera.

The camera may be connected to the apparatus 20 in any suitable manner,as the present invention is not limited in this respect. In oneembodiment, the camera 70 d is connected to the apparatus 20 throughport 78 on the apparatus 20 via an electronic cable 79. In anotherembodiment, an image sensor (e.g., a charge-couple device, also referredto as a CCD) is incorporated into the apparatus 20 rather than withinthe camera 70 d, and a fiber optic cable extending from the camera maybe employed. Further, a fiber optic cable may also be used to transmitdigital code representative of the image viewed by the camera to theapparatus 20, even where the camera includes a CCD. Wireless, Ethernetor modem connections enabling data and image transfer from remotecameras or other sources may also be employed, as the present inventionis not limited to the use of any particular connection technique.

Audio signals from the object being inspected may also be stored and/ortransmitted via the apparatus 20. In one embodiment, the camera 70 d mayinclude a microphone 70 e to pick up such audio. Alternatively, aseparate probe including the microphone 70 e or other such sound orvibration receiving device may be employed.

Error code signals may also be received by the apparatus 20 using asuitable connection 70 f.

In one embodiment, some of the input devices 70 a-70 f may be controlledby the apparatus 20, rather than independent device controls. Forexample, one or more camera control buttons or other interfaces may beprovided on the apparatus and coupled, though the apparatus, to thecamera to allow a user to operate and maneuver the camera 70 d. Cameracontrol may be made via a Motion Control Card (MCC) 97 that is hardwiredto the camera 70 d or otherwise communicates with the camera 70 d via awireless communication. Camera maneuvering may be made using any of theforegoing input devices that may communicate with the MCC. Controland/or maneuvering of the camera includes at least focusing, zooming,change viewing axis, etc., as the present invention is not limited inthis respect. Control of the camera can occur because, in oneembodiment, the camera includes a stepper motor coupled to variouscomponents of the camera, e.g., a gimbal for moving the camera head. TheMCC can control the stepper motor as desired. Alternatively, the camera70 d may be manipulated by hand, as the present invention is not limitedin this respect. Further, a white balance control button 77, intended tocompensate for the amount of ambient light coming into the camera 70 d,may be employed. Control button 77 is internally connected to the CCU.

In one embodiment, the apparatus 20 has at least one output device usedto display and/or store images and data. In one embodiment, an LCD(Liquid Crystal Display) screen 80 a is coupled internally to themotherboard 90 and is visible to the user through a cut-out in thecasing 130. An LCD back light inverter 82 may be employed to control theillumination of the screen 80 a. In one embodiment, the LCD 80 a worksin conjunction with the aforementioned touch screen 70 a to act as bothan input and an output device. Of course, the LCD is one example of adisplay and other suitable displays can be used.

This LCD 80 a may be configured to display image data, video data andtext data in any number of display patterns 84, as shown in FIG. 5. Inone embodiment, the display 84 includes a split screen comprising animage of keys, such as a typical keyboard setup 85, enabling a user totype on the touch screen 80 a using his or her fingers or other suchprobe, and an image display region 86 for displaying the imagedcomponent with related text, if included. In one embodiment, theorientation (landscape or portrait) of images in region 86 can bemanipulated, as will be discussed below. These images may be still orstreaming video, as the present invention is not limited to anyparticular convention. In another embodiment, although not shown, theimage display region may also include a split screen, wherein images andtext data from two or more cameras, each viewing a component, may bedisplayed. Alternatively, the split screen may display stored orhistorical images and/or text of one or more components as well as realtime data. The split screen may also be used to display any of the otheraforementioned data. Additional electronic hardware and software may benecessary to view images in a split screen mode.

An external monitor or television (not shown) may also be attached tothe apparatus 20 and configured as a display in any of the mannersdisclosed above. In one embodiment, the external monitor is connected tothe apparatus 20 via a hardwire connection to a VGA (Video GraphicsArray) port 87. VGA is one of several standards for color monitors.However, it is to be appreciated that other techniques for outputtingvideo may be employed, as the present invention is not limited in thisrespect. In one embodiment, a television is connected to the apparatus20 via a hardwire connection to the aforementioned S-video port.

Additionally, many of the external communication mediums provided asinput devices may also be used as output devices. For example, in oneembodiment, data output is made through the communication medium 70 c,such as a modem, Ethernet or wireless devices. Data may also beoutputted to memory, including the aforementioned flashcard 70 b, themotherboard's internal memory, or any other memory device known to thosein the art, internal or external to the apparatus 20, such as theaforementioned magnetic media, optical media, or electronic media.

In one embodiment, a speaker 80 b may optionally be coupled to theapparatus 20 or otherwise included therein for presenting audio pickedup by the microphone 70 e, whether real-time or previously stored,regarding the object being inspected as well as previously recorded orreal time voice transmission. It is to be appreciated, however, that theuse of audio data and the speaker are not required for all embodiments.

The motherboard 90 controls data flowing in and out of the device andinternal device activity. The motherboard contains the CPU 92, memory,buses, and I/O connection sockets. The CPU can be any suitable processor(e.g., such as a Mobile P3, available from the Intel Corporation, SantaClara, Calif.). The motherboard 90 can be custom designed, or can be anyof numerous commercially available motherboards. One such motherboard 90that may be employed is the Microbus MPX-233111, manufactured byMicrobus Inc. of Houston, Tex. The Microbus MPX-233111 contains a videochip 110 coupled to the motherboard 90 through a COM (serialcommunications) port. This motherboard may be used with a Philips 69000video chip, manufactured by Philips Semiconductors of Eindhoven, TheNetherlands, as the video chip 110. Any other suitable video chip may beemployed. In one embodiment, the CCU 100 is also coupled to themotherboard 90 and is used to control and receive images from one ormore of the external cameras 70 d described above. One example of a CCU100 that may be used is the Panasonic GP-KS162CBPWNTCE manufactured bythe Panasonic Systems Company of Elgin, Ill. Both the video chip 110 andthe CCU 100 aid in manipulating and displaying graphics data. It shouldbe appreciated that the name brand and type of components described areexemplary, as the present invention is not limited in this respect.

Most incoming data flows through the motherboard 90 upon entering theapparatus 20. Input data received via the camera 70 d may be received bythe CCU 100 before being processed by the motherboard 90. The CCU 100 iscapable of controlling one or more parameters of camera generated imagesincluding gain and white light balance and controlling an electroniciris for contrast. In one embodiment, the aforementioned white balancecontrol button 77 is connected to the CCU 100 so that an initial whitebalance reading may be obtained. To take such a reading, the user placesa piece of white paper in front of the camera 70 d and depresses thewhite balance control button 77. The CCU 100 uses this reading tomeasure the amount of ambient light. Then, the CCU 100 uses the readingto adjust the color data in all subsequent camera shots, compensatingfor the ambient light.

The CCU can also perform analog to digital (A/D) conversion. Forexample, the CCU may receive images in any electronic format from thecamera and reformat the images into digital format. The CCU then passesthe digitally formatted image to the CPU.

The video chip 110 can perform a variety of image manipulations on anyimage, and is not limited to manipulating solely camera generatedimages. In some embodiments, the video chip 110 is capable of A/Dconversion, as well as formatting the image into known image formats,such as JPEG (Joint Photographic Experts Group). Once formatted byeither or both of the CCU 100 and the video chip 110, the data may bepassed to the CPU 92 for further processing, storing and/ortransmitting.

The CPU 92 retrieves any requested data and sends it to the properoutput device as requested. The CPU 92 also processes, stores or sendsany inputted data as directed. Software used in the apparatus 20 may berun by and controlled by the CPU 92. Such software may be customsoftware or commercially available software, such as XFREE86 provided byThe XFree86 Project, Inc (available from the University of Sydney,Australia) that runs on UNIX® and compatible (e.g., Linux, BSD, Mac OS Xand Solaris x86 series) operating systems and OS/2 and a suitablewindows manager. This or other software may be used so that the CPU canperform concurrent operations of two or more processes in a multitaskfashion. In one embodiment, Linux operating system is run on theapparatus, available from Linux.com. Other suitable operating systemsmay be employed as the present invention is not limited in this respect.

Word processing or other text processing software may be employed tohandle partial or full text inputs by a user. In this respect, any textinformation that a user desires may be inputted, not merelypre-programmed information. Of course, pre-programmed information, suchas checklists, may also be employed. The images or audio data may beattached as a file to the text resulting text file.

Additional software may include an image manipulation package, enablingthe data to be formatted according to certain display constraints. Somepossible manipulations may include image rotation, image sizing andchoosing between landscape and portrait display options. The CPU 92 mayemploy any of a number of algorithms to handle these tasks, as will beexplained below. In one embodiment, the memory 94 is used to bufferseveral frames of incoming streaming video such that the images can beprocessed frame by frame and then displayed to the user at a ratecomparable to that of real time, but several microseconds later. Thisprocess improves display quality and facilitates image manipulation. Forexample, each frame in the buffer may be rotated prior to beingdisplayed to the user.

The CPU 92 can interface with the motherboard's memory 94 in any ofnumerous ways, e.g., through various busses. In one embodiment, themotherboard 90 contains 64 MB of RAM (Random Access Memory). However,the present invention is not limited by the type or amount of storageplaced on the motherboard 90, as additional types or amounts may becoupled to the motherboard 90. In the embodiment shown, both the memory94 and the CPU 92 interface with the I/O devices through the I/Oconnection.

In one embodiment, a power supply interface is provided by a port 112capable of hardwire connection to an external power supply. The powersupply level may be about 12 V, or other levels may be employed. Theapparatus 20 can include an on-board power source, such as a battery 114(FIG. 4), which may be rechargeable and housed within the casing,thereby rendering the apparatus 20 cordless.

As discussed above, the various components forming the apparatus 20 maybe housed within a casing 130. In one embodiment, the casing 130includes a front casing 130 a and a back casing 130 b that interconnectto form an enclosure. The front casing 130 a contains a cutout 132 forthe display screen 80 a and touch screen 70 a. The back casing 130 b issubstantially rectangular and may also one or more cutouts 134 for portsto external devices and/or control buttons, knobs, switches or otherinterfaces.

The front and back casings 130 a, 130 b may be secured together usingany suitable technique, such as with the use of screws. In addition, thecasing 130 may contain various bosses to support and secure the variouselectronic and mechanical components of the apparatus 20.

In one embodiment, the casing 130 also contains two sets of four curvedfinger grooves 136 on the external side to aid in handling the apparatus20. Handles 138 are attached to the casing 130 over these groves,leaving about a one to two inch space for a user's hands. A hook 140 maybe mounted to the case to allow the apparatus 20 to be hung forhands-free use. It should also be recognized that casing for theapparatus 20 can take many other shapes and configurations, as notlimited. The casing 130 of the apparatus 20 may be manufactured out ofmany types of material in order to satisfy the needs of the user. Forexample, the apparatus 20 may be ruggedized and/or waterproofed.

In addition, it should be appreciated that various aspects of thepresent invention are not limited to the use of this or any particularhardware particularly adapted for use as a digital maintenanceapparatus. For example, many of the above-described methods may beprogrammed into any suitable computer.

As discussed above, any suitable type of imaging unit or camera can beused with the apparatus 20 to provide images of the object 24. Oneexample of an imaging system, including a camera assembly and a scope,with which the apparatus 20 of the present invention can be used, willnow be described with reference to FIGS. 6-10. However, it is to beappreciated that the apparatus 20 is not limited to use with this or anyother particular imaging system.

FIG. 6 is a partially cut away perspective view of an example of animaging system that may be used with the apparatus 20. As shown, theimaging system includes four primary components, i.e., a scope 150, suchas an endoscope, an imaging unit or camera assembly 152, a coupler 154,which couples the scope 150 to the imaging unit 152, and a condom-likedrape 400, which prevents the imaging unit 152 from contaminating asterile operating field should the system be used in a medicalenvironment, a clean room environment for the manufacture of e.g.,silicon wafers, or other sterile environments. The use of thecondom-like drape 400 need not be employed when inspecting components,such as aircraft engines. The imaging system can be employed with anytype of image-producing scope, and is not limited to use with anyparticular type of scope.

As discussed in more detail below, in the exemplary imaging system shownin FIGS. 6-7, the condom-like drape 400 does not intercept the opticalviewing axis of the system. In addition, the condom-like drape 400 doesnot cover a focusing mechanism 480 of the imaging system, making iteasier to focus the system and lessening the likelihood that the drape400 will be damaged due to manipulation of the focusing mechanism.

The lens for focusing the image from the endoscope to the imaging unitmay be provided in the imaging unit 152, rather than in the coupler 154.This is particularly advantageous because, as discussed in more detailbelow, in the exemplary embodiment shown, a portion of the coupler 154is not separated from the scope 150 by the condom-like drape 400, andtherefore, is sterile in use. By removing the refractive lens 200 fromthe coupler 154, the coupler 154 can be made significantly lessexpensively, thereby enabling the coupler 154 to be provided as adisposable part that need not be sterilized between uses. This isadvantageous because the sterilization of the devices can beinconvenient and time consuming.

The imaging unit 152 includes an image sensor 156 that senses an imagealong an imaging axis (not shown). When the imaging system is used, thecoupler 154 is coupled between the eyepiece 158 of the scope 150 and adistal end 660 of the imaging unit 152 such that the lens 200 isdisposed between the image sensor 156 and the eyepiece 158 to focus animage produced by the scope 150 onto the image sensor 156. Therefractive lens 200 may be provided in the imaging unit 152, rather thanin the coupler 154. The coupler can be therefore made significantly lessexpensively, thereby enabling the coupler to be provided as a disposablepart that need not be sterilized between uses.

The image sensor 156 may, for example, include a charge-coupled device(CCD) as discussed above, or a metal-oxide semiconductor (MOS) sensor.It should be appreciated, however, that the present invention is notlimited in this respect, and can be employed with any type of imagesensor 156. The image generated by the image sensor 156 can be conveyedto the maintenance apparatus 20 or a monitor 460 in any of numerousways, and the present invention is not limited to any particularimplementation. For example, the image sensor 156 may be coupled tocircuitry 560 which can assist in converting an image sensed by theimage sensor 156 into an electrical signal. This electrical signal thenmay be transmitted (e.g., via cable 260) to the monitor 460, maintenanceapparatus 20 or elsewhere for display to a user or may be otherwiseprocessed and/or recorded on a suitable medium. Alternatively, the imagesensor 156 may comprise a bundle of fiber optic cables which opticallytransmit an image from the lens 200 to the apparatus 20 or other aviewing device for display to a user. Thus, the image sensor 156 neednot necessarily convert the image from scope 150 into an electricalsignal.

The imaging unit 152 is releasably mated with the coupler 154. Thismating may be accomplished using any of a number of techniques. FIGS. 6and 7 illustrate one technique that may be used to mate these twocomponents. In the particular implementation shown, to mate imaging unit152 with coupler 154, a distal end 660 of the imaging unit 152 isinserted into an opening 880 at a proximal end 1100 of the coupler 154.As shown, the imaging unit 152 includes a button 580 which is pivotallyconnected, via a pin 820, to a body portion 180 of the imaging unit 152.The imaging unit 152 has a cavity 810 formed underneath the button 580and a spring 900, disposed in the cavity 810. Spring 900 biases thebutton 580 (in a clockwise direction in FIG. 6) about pin 820 so thatlocking member 600 is biased away from a surface 860 of body portion180. When a user pushes button 580 toward surface 860, however, spring900 is compressed so that button 580 moves in a counterclockwisedirection in FIG. 6 about pin 820 and locking member 600 moves towardsurface 860. Thus, when the button 580 is depressed and the distal end660 of the imaging unit is inserted into the opening 880 in the coupler154, the locking member 600 moves toward surface 860 so that it canslide over edge 1180 of the coupler 154. When the button 580 isreleased, the locking member 600 is biased (by spring 900) away fromsurface 860 and into a notch 620 in the coupler 154, and a shoulder 1160of imaging unit 152 contacts a shoulder 1140 of the coupler 154, therebyinterlocking the imaging unit 152 and the coupler 154. An indicationthat the distal end 660 of the imaging unit 152 is fully inserted intothe opening 880 is provided by the distal end 660 contacting a shoulder1120 of coupler 154. The imaging unit 152 and coupler 154 can beseparated by pushing button 580, which moves the locking member 600 outof the notch 620, and pulling the imaging unit 152 away from the coupler154. As mentioned above, FIGS. 6 and 7 illustrate only one example ofthe many ways that the imaging unit 152 and coupler 154 may be matedtogether.

As shown in FIGS. 6 and 7, the imaging unit 152 also includes a handle780 proximal to the body portion 180. The handle 780 may include grooves800 to make it easier for a user to grip the imaging unit 152 though thedrape 400 that can be extended over the imaging unit 152 in a mannerdescribed below.

The image sensor 156 and circuitry 560 may be mounted in the bodyportion 180 of the imaging unit 152 in any of a number of ways. Forexample, the image sensor 156 may be mounted via pins or screws 840 aand 840 b, and circuitry 560 may be mounted on a circuit board supportedwithin body portion 180. One or more wires (not shown) may be used tointerconnect the circuitry 560 with the cable 260.

It may be useful to enable the focal length between the image sensor 156and the lens 200 of imaging unit 152 to be adjusted. In the system shownin FIGS. 6-7, this is accomplished via a mechanism that is not coveredby the condom-like drape 400, thereby making it easier to focus thesystem and lessening the likelihood that the drape 400 will be damageddue to manipulation of the focusing mechanism. It should be appreciated,however, that the focal length adjustment can be accomplished in anynumber of ways.

One example of a technique that is useful to perform the focal lengthadjustment is illustrated in FIGS. 6-8. In the embodiment shown, therefractive lens 200 is disposed in the imaging unit 152, rather than inthe coupler 154. Thus, the focusing mechanism includes elements disposedin the imaging unit 152, as well as in the coupler 154. As mentionedabove, placement of the lens 200 within the imaging unit 152, ratherthan in the coupler 154, provides at least one significant advantage.That is, the cost of the coupler 154 may be reduced significantly belowthe cost of coupling devices that include lenses, thereby making itcommercially practicable to use a new, sterile coupler each time theimaging system is used, rather than repeatedly sterilizing and reusingthe same coupling device should sterilization be required.

The distal end 660 of the imaging unit 152 includes a primary cylinder760, in which a spring 680 and a cylindrical lens holder 220 aredisposed. Lens holder 220 supports the lens 200 in front of an imagingaxis of image sensor 156. Lens holder 220 (and lens 200) can be movedwithin primary cylinder 760 either toward or away from to distal end 660of the imaging unit 152 so as to adjust the focal length between theimage sensor 156 and the lens 200. Spring 680 biases lens holder 220toward distal end 660. The position of lens holder 220 within primarycylinder 760 can be adjusted, however, through manipulation of afocusing mechanism on the coupler 154 as discussed below. It should beappreciated that the present intention is not limited in this respectand that a camera including a lens that does not require focussing maybe employed.

The imaging unit 152 further includes an outer cylinder 720, including aspirally ramped upper edge 960, which surrounds the primary cylinder760. Outer cylinder 720 is movable with respect to primary cylinder 760either toward or away from the distal end 660 of imaging unit 152. Outercylinder 720 is connected to the lens holder 220 via a pin 700. Pin 700extends through a slot 920 which extends a short distance along a lengthof the primary cylinder 760. Thus, lens holder 220, outer cylinder 720and pin 700 move as a single unit, with respect to primary cylinder 760,either toward or away from the distal end 660 of imaging unit 152. Themanner in which this unit interacts with the focusing mechanism disposedon coupler 154 is described below in connection with FIGS. 8a-8 b.

FIGS. 6 and 7 show an exemplary implementation of the coupler 154. Thecoupler 154 can be constructed in any of a number of ways to achieve thedesired goal of enabling the imaging unit 152 to be coupled to the scope150. In the implementation shown, the coupler 154 includes a main body500 (including a proximal portion 500 a and a distal portion 500 b), afocusing ring 480, a light-penetrable window 940, a scope mountingportion 420 (including inner ring 420 a and outer ring 420 b) and thecondom-like drape 400. The components constituting the main body 500,focusing ring 480 and scope-mounting portion 420 may be made of anysuitable material and may be affixed together in any suitable manner.For example, they may be plastic molded components affixed togetherusing an epoxy-based adhesive. When the coupler 154 is a disposabledevice, the coupler 154 is preferably formed from inexpensivecomponents.

The main body 500 may be formed by inserting the distal portion 500 bwithin the focusing ring 480, and then affixing together the proximaland distal portions 500 a and 500 b. Scope mounting portion 420 may beaffixed to distal portion 500 b. Main body 500 has an outer surface 520between a distal end 1080 and a proximal end 1100 of the coupler 154. Achannel 440 extends about a perimeter of the outer surface 520 betweenthe focusing ring 480 and the proximal end 1100.

When the coupler 154 is used in a medical or clean room application, itis desirable to not have to sterilize the imaging unit 152, therebysaving the time and expense of sterilization, and avoiding restrictionson the manner in which the imaging unit be formed, since it need not besterilizable. Therefore, a sterile barrier may be established betweenthe sterile operating environment including the scope 150, and anon-sterile environment including the imaging unit 152. In the systemshown in FIGS. 6-7, such a sterile barrier is established by couplingthe distal end 660 of the imaging unit 152 to the coupler 154, andproviding a hermetic seal between the components of the coupler 120 thatseparate the sterile and non-sterile environments. A light-penetrablewindow 940 is hermetically sealed between the distal end 1080 and theproximal end 1100 of the coupler 154 to establish a sterile barriertherebetween. Window 940 may be made of glass, plastic, or any othersuitable material through which light can pass from the scope 150 to theimage sensor 1 56 (via lens 200) to generate a suitable image.

As mentioned above, the coupler 154 also includes the condom-like drape400. The condom-like drape 400 may be made of any material that issuitable for creating a sterile barrier between a sterile environmentand a non-sterile environment. For example, the condom-like drape may bemade of a non-porous latex or plastic material. When the imaging unit152 is mated with the coupler 154, the drape 400 may be extended tocover some or all of imaging unit 152 and cable 260. The condom-likedrape 400 may be hermetically sealed to the outer surface 520 of coupler154. It should be appreciated that in the implementation shown in thefigures, when each of the components of the coupler 154 is sterile, thehermetic seals between the main body portion 500 and the window 940 anddrape 400 establish a sterile barrier between the scope 150 and theimaging unit 152, with the main body portion 500 of the coupler 154itself forming a part of this sterile barrier. As compared to othersystems, in which a sterile barrier is formed only with a drape and awindow portion thereof and in which a coupling device is locatedentirely on the non-sterile side of this barrier, the system shown inFIGS. 8 and 9 is superior because scope 150 can mate directly with bodyportion 500 rather than requiring the drape to be interposed between thecoupling device and the endoscope.

In the system shown in the figures, the condom-like drape 400 does notintercept the optical viewing axis 190 of the imaging system. Asmentioned above, this is advantageous in that the drape 400 need not beprovided with a window that must be aligned with the optical viewingaxis 190, and the drape 400 does not interfere with the quality of theimage presented on the monitor 460. It should be appreciated that thefunction performed by the condom-like drape 400 can be achieved in anyof numerous ways. For example, a protective drape can be provided thatis more rigid than the condom-like drape 400 depicted in the drawings.

In the system shown in the drawings, the condom-like drape 400 issubstantially tubular in form and is open on its distal and proximalends. The distal end 210 of the condom-like drape 400 is attached to theouter surface 520 (within channel 440) of the coupler 120. As discussedabove, this attachment can be accomplished using a hermetic seal (e.g.,via an O-ring 540) to maintain the separation between the sterile andnon-sterile environments. The condom-like drape 400 can be provided in arolled-up form attached to the coupler 154. After the coupler 154 ismated with to the imaging unit 152 as described above, the condom-likedrape 400 can be unrolled to cover the non-sterile imaging unit 152. Byencompassing the outer surface 520 of coupler 154 with the opening atthe distal end 210 of the drape 400, the drape 400 can be used inconjunction with coupler 154 without requiring the user to align thedrape 400, or a window portion thereof between the eyepiece 158 of thescope 150 and the coupler 154, and without having the drape 400intercept the optical viewing axis 190 of the imaging system. Asdiscussed above, it is to be appreciated that the use of a drape isoptional.

FIGS. 6 and 7 illustrate one example of a technique that may be used tomate the scope 150 with the coupler 154. It should be appreciated thatnumerous other suitable mating techniques can be employed. In the systemshown in FIGS. 6 and 7, the scope 150 is mated with the coupler 154 byinserting the eyepiece 158 into an opening 380 at the distal end 1080 ofthe coupler 154. Opening 380 may be formed by the inner and outer rings420 a-420 b of the scope mounting portion 420. The inner and outer rings420 a-420 b form equal diameter openings, and inner ring 420 a ismovable with respect to outer ring 420 b. A spring biases the inner ring420 a so that its center is forced to be offset from the center of theouter ring 420 b unless a user activates a lever (not shown) to causethe centers of the two rings to align with one another.

To mate the scope 150 with the coupler 154, the user activates the leverso that the centers of the rings 420 a-420 b align with one another andinserts the eyepiece 158 through both rings. The user then can releasethe lever so that the spring (not shown) causes the center of ring 420 ato become offset from the center of ring 420 b. Because the diameter ofthe eyepiece 158 is only slightly smaller than the diameter of each ofrings 420 a and 420 b, when the centers of the rings are offset from oneanother, the eyepiece 158 will be locked within the scope mountingportion 420 of the coupler 154. The eyepiece 158 may be separated fromthe scope mounting portion 420 by pressing the lever to realign thecenters of rings 420 a and 420 b and pulling the scope 150 away from thecoupler 154.

In the system of FIG. 6, the coupler 154 is shown as being mateddirectly with the eyepiece 158 of the scope 150. However, it should beappreciated that the scope 150 (or other image-producing scope) mayalternatively be mated indirectly with the coupler 154. For example, thescope 150 may be mated with the coupler 154 via one or more additionalcoupling devices.

As discussed above, using the system of FIGS. 6-8, the user can directlymanipulate a focusing mechanism without having to do so through aportion of a protective drape such as condom-like drape 400. Anyfocusing mechanism can be employed that serves to adjust the focallength between the lens 200 and image sensor 156 in the imaging unit152. In the exemplary system shown in FIGS. 6-8, a focusing ring 480 isprovided on the coupler 154 to perform this focal length adjustment. Thefocusing ring 480 is disposed distally of the distal end 210 of thecondom-like drape 400, so that after the drape 400 is extended to coversome or all of the imaging unit 152 and cable 260, the focusing ring 480is not covered by the drape 400 and may be manipulated by a user toadjust the focal length between the lens 200 and the image sensor 158without also having to manipulate the drape 400. Hence, this featuremakes focusing ring 480 relatively easy for the user to manipulate toachieve sharp focusing, and reduces the risk of damage to drape 400.

An illustrative example of a linkage assembly for mechanically couplingthe focusing ring 480 on the coupler 154 to the imaging unit 152 toadjust the focal length between the lens 200 and image sensor 158 isshown in FIGS. 7, 8 a and 8 b. It should be appreciated that numerousother implementations are possible. In the system shown, the distalportion 500 b of the main body portion 500 of coupler 154 has an annulargroove 1000. Annular groove 1000 may be covered by the focusing ring480, so that it is not visible from the outside of coupler 154. A finger980 extends inwardly from the focusing ring 480 through the annulargroove 1000, so that when the focusing ring 480 is rotated about themain body portion 500, finger 980 slides within the annular groove 1000.

As shown in FIGS. 8a and 8 b, when the imaging unit 152 is mated withthe coupler 154, a lower surface 1200 of finger 980 contacts a portionof a spiraling ramp surface 960 on the outer cylinder 720. As mentionedabove, pin 700 may be connected between the outer cylinder 720 and thecylindrical lens holder 220 through the slot 920, which extends alongthe length of the primary cylinder 760, so that the outer cylinder 720and lens holder 220 do not rotate with respect to the primary cylinder760. The focusing ring 480, however, can rotate freely about the primarycylinder 760, limited only by the movement of the finger 980 within theannular groove 1000.

As the focusing ring 480 rotates with respect to the primary cylinder760, a bottom surface 1200 of the finger 980 slides along the spiralingramped surface 960. The spring 680 pushes upwardly on outer cylinder 720to keep a portion of the spiraling ramped upper surface 960 in contactwith bottom surface 1200 of the finger 980 at all times. Enough frictionexists between the focusing ring 480 and the main body 500 of thecoupler 154 to prevent the spring 680 from rotating the focusing ring480 when it is not being manipulated by a user. This friction makes thefine tuning of the focal length between the lens 200 and image sensor156 (using focusing ring 480) relatively easy to accomplish.

FIGS. 8a and 8 b illustrate the focusing mechanism at its two extremefocusing positions, with FIG. 8a illustrating the lens 200 at itsclosest position to the image sensor 156 and FIG. 8b illustrating thelens 200 at its furthest position from the image sensor 156. As shown inFIG. 8a, when the lens 200 is at its closest position to the imagesensor 156, the spring 680 is fully compressed, bottom surface 1200 offinger 980 is in contact with a point 1060 near the top of the spiralingramped surface 960, and the finger 980 is in a first position withrespect to the primary cylinder 760. In contrast, as shown in FIG. 8b,when the lens 200 is at its furthest position from the image sensor 156,the spring 680 is fully extended, the bottom surface 1200 of finger 980is in contact with a point 1040 near the bottom of the spiraling rampedsurface 960, and the finger 980 is in a second position with respect tothe primary cylinder 760, which is on an opposite side from the firstposition (FIG. 8a).

It should be appreciated that the above-described system for adjustingthe focal length between the image sensor 156 and the lens 200 is onlyone example of the many possible systems that can achieve this result,as other implementations can alternatively be employed.

In the illustrative embodiment of FIGS. 6-7, the imaging unit 152includes a single body portion 180 in which both the image sensor 156(and associated circuitry 560) and the refractive lens 200 (andassociated components such as the lens holder 220, the spring 680, andthe cylinders 720 and 760) are disposed. It should be appreciated,however, that various components of the imaging unit 152 mayalternatively be distributed among two or more separate housings thatmay be mated together to form the imaging unit 152. An illustrativeexample of an imaging system configured in this manner is shown in FIGS.9 and 10. As shown in FIG. 9, the imaging unit 152 to be mated with thecoupler 154 may include a first housing 180 a in which the refractivelens (and associated components) is disposed, and a second housing 180 bin which the image sensor 140 (and associated circuitry (not shown)) isdisposed.

In the illustrative embodiment shown in FIGS. 9 and 10, the secondhousing 180 b is the housing of a camera head 152 b (e.g., a standardC-mount camera head), and the first housing 180 a is the housing of anadapter 152 a for adapting the camera head 152 b for use with thecoupler 154. When the adapter 152 a is mated with the camera head 152 b(as discussed below), the adapter 152 a and the camera head 152 btogether form a composite imaging unit 152 which is similar to theimaging unit 152 described above in connection with FIGS. 6-7. Althoughthe example shown in FIGS. 9-10 includes a C-mount camera head andadapter therefor, it should be appreciated that each of the housings 180a-180 b may take on any of a number of alternative forms. For example,the housing 180 b may alternatively be the housing of a standard V-mountcamera head, or any other device in which an image sensor is disposed,and the housing 180 a, may be configured to be mated with the same.

It should also be appreciated that the imaging unit 152 may furtherinclude additional housings, including only one or two housings. Forexample, referring to the FIG. 9 system, the imaging unit 152 mayfurther include one or more housings disposed between the housings 180 aand 180 b or between the housing 180 a and the coupler 154. Such anadditional housing may exist, for example, in the form of a couplingdevice that couples together the housings 180 a and 180 b or the housing180 a and the coupler 154. It should be appreciated that the imagingunit actually employed may be any of numerous devices or combinations ofdevices capable of receiving an optical image along an imaging axis. Asused herein, the term “imaging unit” is not intended to be limiting.Rather, it is intended to refer to any device or combination of devicescapable of performing an imaging function.

Further, while in the systems of FIGS. 6-9 the coupler 154 is shown asbeing mated directly with the distal end 660 of the imaging unit 152, itshould be appreciated that the imaging unit 152 may alternatively bemated indirectly with the coupler 154. For example, the imaging unit152, in whatever form, may be mated with the coupler 154 via one or moreadditional coupling devices.

In the illustrative system shown in FIGS. 9-10, the operationalinterface between the adapter 152 a and the coupler 154 is identical inmost respects to the operational interface between the imaging unit 152and the coupler 154 described above in connection with FIGS. 6-8.Corresponding components in the two embodiments have therefore beenlabeled with identical reference numerals, and reference may be made tothe description of the embodiment of FIGS. 6-8 for an in-depthunderstanding of the operational interface between the adapter 152 a andthe coupler 154 of the embodiment of FIGS. 9-10.

As mentioned above, the camera head 152 b may, for example, be astandard C-mount camera head. Therefore, as shown in FIG. 9, the camerahead 152 b may include a threaded, female connector 1280 formed at adistal end 1320 thereof. To permit the adapter 152 a to mate with theconnector 1280 of the camera head 152 b, the adapter 152 a may include athreaded, male connector 1260 formed at a proximal end 1360 thereof.

As shown in FIG. 9, the image sensor 156 may be disposed adjacent thedistal end 1320 of the camera head 152 b so that, when the maleconnector 1260 of the adapter 152 a is threaded into the femaleconnector 1280 of the camera head 152 b, the image sensor 156 isdisposed adjacent an opening 1380 at the proximal end 1360 of theadapter 152 a. In the system of FIGS. 9-10, the image sensor 156 istherefore disposed further from the distal end 660 of the imaging unit152 than it is in the system of FIGS. 6-7. For this reason, in thesystem of FIGS. 9-10, an annular cavity 1220 is formed within thehousing 180 a to provide an optical pathway between the refractive lens200 and the image sensor 156 along which an image produced by the scope150 can be focused onto the image sensor 156 via the lens 200. Thecavity 1220 may be formed, for example, by reducing a width of anannular shoulder 1340 (FIG. 10) supporting one end of the spring 680 tobe narrower than in the embodiment of FIGS. 6-7.

In addition, in the system of FIGS. 9-10, the button 580 is disposed onthe adapter 152 a of the imaging unit 152, and is therefore disposeddistally of the image sensor 156 in this system, rather than proximallyof the image sensor 156 as in the system of FIGS. 6-7. As shown, to makethe button 580 fit on the adapter 152 a, the button 580 may be shortenedas compared to the system of FIGS. 6-7. Additionally, the pin 820 aboutwhich the button 580 pivots may be disposed within a small cavity 1240adjacent the proximal end 1360 of the adapter 152 a, rather than beingdisposed proximally of the image sensor 156 as in the system of FIGS.6-7. It should be appreciated, of course, that the button 580 andlocking member 600 represent only one example of numerous mechanismsthat can be used to interconnect the imaging unit 152 with the coupler154, and that the imaging unit 152 may be mated with the coupler 154 indifferent ways. For example, the imaging unit 152 may not include abutton such as the button 580 or a locking member such as the lockingmember 600 at all, and may instead provide a different mechanism formating the imaging unit 152 with the coupler 154.

In light of the above description, it should be appreciated that, as faras the physical interface between the imaging unit 152 and the coupler154 is concerned, the imaging unit 152 that is formed when the adapter152 a is mated with the camera head 152 b can be made identical in allrespects to the imaging unit 152 of embodiment of FIGS. 6-8.Additionally, by properly adjusting the refractive index of the lens 200to account for the increased distance between the distal end 660 and theimage sensor 156 in the embodiment of FIGS. 9-10 as compared to theembodiment of FIGS. 6-8, the imaging unit 152 of FIGS. 9-10 can also bemade to mimic the functional characteristics of the imaging unit 152 ofFIGS. 6-8 as well. The use of the adapter 152 a of FIGS. 9-10 thereforeenables a standard camera head (e.g., the camera head 152 b) to beadapted for use with the inventive coupler 154 described herein in thesame manner as in the embodiment of the imaging unit 152 described inconnection with FIGS. 6-8. Therefore, one already in possession of acamera head 152 b (e.g., a standard C-mount or V-mount camera head) maysimply purchase the adapter 152 a(which does not include an imagesensor) for use with the coupler 154, rather than purchasing the imagingunit 152 of FIGS. 6-8 (which additionally includes an image sensor) foruse therewith.

The adapter 152 a described herein is configured for use with a specifictype of coupler (i.e., the coupler 154). However, it should beappreciated that the adapter 152 a may alternatively be configured foruse with other types of devices or couplers.

It should be appreciated that any suitable type of camera can be used totake such images, as the present invention is not limited to theabove-described examples. Additional examples of cameras that can besuitable for use in such a system are described in a series ofApplicant's earlier-filed U.S. patent applications, includingprovisional applications 60/054,197; 60/054,198; and 60/121,382, as wellas regular U.S. patent applications Ser. Nos. 09/126,368; 09/382,496;and 09/513,673, each of which is incorporated herein by reference.However, the present invention is not limited to using such camerasystems.

The apparatus 20 and method of use described herein can be used inconnection with inspection and/or maintenance of numerous types ofobjects, as the present invention is not limited in this respect. Theapparatus 20 and method of use described herein can be used inconnection with inspection and/or maintenance of: aircraft (e.g.,airplanes and helicopters), boats, automobiles, trucks, militaryequipment (e.g., tanks, weapons, etc.) and space vehicles; engines andrelated components, including aircraft engines, ship engines, motorvehicle engines and turbine engines; structural components of vehicles,such as airframes, hulls, chassis and automobile frames and other suchcomponents; structures such as buildings, roads, bridges, tunnels, etc.;facilities such as manufacturing plants and power plants including thecomponents or objects relating to such facilities; mechanicalcomponents; systems; parts; inventory; products; processes; fluids andflows; and chemicals. Other applications for the apparatus include, butare not limited to, capturing, storing and retrieving information, suchas maintenance and/or inspection information, regarding: processcontrol; inventory management and control; cargo inspection by customsagents; searches conducted by law enforcement officials; surveillance;and obtaining diagnostic and other information by doctors and othermedical professionals. Other applications will be readily apparent tothose of skill.

It should be appreciated that various combinations of theabove-described embodiments of the present invention can be employedtogether, but each aspect of the present invention can be usedseparately. Therefore, although the specific embodiments disclosed inthe figures and described in detail employ particular combinations ofthe above-discussed features of the present invention, it should beappreciated that the present invention is not limited in this respect,as the various aspects of the present invention can be employedseparately, or in different combinations. Thus, the particularembodiments described in detail are provided for illustrative purposesonly.

What is claimed is:
 1. A method of inspecting an aircraft or an aircraftcomponent from a remote location, the method comprising acts of: loadinga desired maintenance program into an inspection apparatus, theapparatus having a computer and a camera control unit coupled to thecomputer and adapted to receive and process images from an imager thatis housed separately from the camera control unit, the apparatus beingcapable of capturing, together with the imager, both a streaming videodigital image of the aircraft or aircraft component and a still digitalimage of the aircraft or aircraft component; instructing the sameapparatus to capture, together with the imager, at least one of a) thestreaming video digital image of the aircraft or an aircraft componentat a first location and b) the still digital image of the aircraft or anaircraft component at a first location; operating the same apparatus toenter in the program remarks about the aircraft or aircraft component,the remarks including at least one of notes regarding a condition of theaircraft or aircraft component, a date the image was taken, anidentification of the aircraft or the aircraft component, and anidentification of a person using the apparatus; instructing the sameapparatus to electronically transmit the at least one of streaming videodigital image, still digital image and remarks to a second locationremote from the first location; reviewing the at least one of streamingvideo digital image, still digital image and the remarks at the secondlocation; preparing instructions based on at least one of the streamingvideo digital image, still digital image and remarks; transmittinginstructions back to the first location; and performing maintenance onthe aircraft or an aircraft component in response to the instructions.2. The method according to claim 1, further comprising an act ofstoring, in the apparatus, at least one of an image of the initialcondition of the aircraft or aircraft component, maintenance history ofthe aircraft or aircraft component, diagnostic information regarding theaircraft or aircraft component and instructional information regardingthe aircraft or aircraft component.
 3. The method according to claim 1,further comprising an act of operating the same apparatus to enter inthe program audio data regarding the aircraft or aircraft component. 4.The method according to claim 3, further comprising an act ofinstructing the same apparatus to electronically transmit the audio datato the second location.
 5. The method according to claim 1, furthercomprising an act of obtaining an error code regarding the aircraft oraircraft component.
 6. The method according to claim 5, furthercomprising an act of instructing same apparatus to electronicallytransmit the error code to the second location.
 7. The method accordingto claim 1, wherein the act of entering remarks in the program about theaircraft or aircraft component comprises an act of inputting in theprogram at least one of text and voice.
 8. The method according to claim1, wherein the act of instructing the same apparatus to transmit theimage comprises an act of instructing the same apparatus to transmit theimage via a wireless connection.
 9. The method according to claim 1,wherein the act of instructing the same apparatus to the image comprisesan act of instructing the same apparatus to transit the image via theInternet.
 10. The method according to claim 1, wherein the act ofinstructing the apparatus to capture, together with the imager, at leastone of a) a streaming video digital image of the aircraft or aircraftcomponent at a first location or b) still digital image of the aircraftor aircraft component at a first location comprises an act ofinstructing the apparatus to capture, together with the imager, a stilldigital image of the aircraft or aircraft component at a first location.11. The method according to claim 1, wherein the act of instructing theapparatus to capture, together with the imager at least one of a) astreaming video digital image of the aircraft or aircraft component at afirst location or b) a still digital image of the aircraft or aircraftcomponent at a first location comprises an act of instructing theapparatus to capture, together with the imager, a streaming videodigital image of the aircraft or aircraft component at a first location.12. The method according to claim 1, wherein the act of instructing thesame apparatus to electronically transmit the at least one of streamingvideo digital image and still digital image comprises an act ofinstructing the same apparatus to electronically transmit the at leastone of streaming video digital image and still to at least one of amanufacturer of the aircraft and a manufacturer of the aircraftcomponent.
 13. The method according to claim 1, wherein the act ofinstructing the same apparatus to electronically transmit the at leastone of streaming video digital image and still digital image comprisesan act of instructing the same apparatus to electronically transmit theat least one of streaming video digital image and still image to anaircraft maintenance facility.
 14. The method according to claim 1,wherein the act of transmitting instructions to the first locationcomprises an act of transmitting maintenance instructions to the firstlocation.